System and method for tracking welding-type parameters, machine setup and job packet coding for workflow

ABSTRACT

A system and method for identifying, recording, and storing specific settings for an interface device of a welding-type system includes a bezel forming a marking surface that extends about a portion of a periphery of the interface device to display user markings and allow the markings to be selectively erased. The marking surface may be designed to receive color-coded markers that engage the marking surface through suction, magnetism, or peg-and-receptacle couplings to indicate desired settings of the interface device to perform a specific welding-type process. Additionally, if the interface device is a dial, a pointer may be coupled with the dial that is movable independently from the dial to indicate a desired dial setting.

REFERENCE TO RELATED APPLICATIONS

Not applicable.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

BACKGROUND OF THE INVENTION

The present invention relates generally to welding-type systems and,more particularly, to a system and method for tracking or identifyingwelding-type parameters for machine set up and workflow through awelding-type process. A plurality of components is provided thatfacilitate identifying and recording operational parameters and guidingan operator through a welding-type process.

Welding-type systems, such as welding systems, plasma cutting systems,induction heating systems, and the like, include a complex set ofcomponents. For example, welding systems often include a power source, aplurality of cables, and a welding gun or torch and may also includewire feeders, gas sources, and many other components. Likewise, plasmacutters typically include a power source, cutting torch, gas source, anda variety of cables that connect these components. Not only must suchcomponents be coupled together correctly to perform a welding-typeprocess, operational settings, such as voltage, wire feed speed and thelike, must be correctly selected for the particular welding-type processbeing performed and the workpiece on which the process is beingperformed. Accordingly, welding-type processes require skilledoperators, often with years of experience.

However, when an operator has yet to gain the requisite experience orwhen a skilled operator is required to perform an unfamiliar process oruse an unfamiliar welding-type system, proper selection and coupling ofcomponents and proper selection of operational parameters can be adifficult, if not daunting, task. Accordingly, in some cases recordbooks or charts are used to record a listing of operational parametersfor a given welding-type system when performing a particularwelding-type process. The books or charts are sometimes associated witha particular welding-type system or, in some instances, operators usemarkers to write directly on the welding-type system. Accordingly,systems such as the Miller Mark VI available from Miller Electric Mfg.Co. have been developed that include an individual dry erase board thatis attached to the welder. While such systems for recording operationalparameters are useful, they do not aid in the proper identification andassembly of the individual components of the welding-type system andthey require the operator to properly correlate the recorded operationalparameters to specific user interface settings.

Therefore, it would be desirable to have a system and method fortracking or identifying welding-type parameters and workflow through awelding-type process. Specifically, it would be desirable to have asystem and method for directly identifying proper components, settingsand workflow for a given welding-type process and for directly recordingand correlating desired operational parameters for the welding-typeprocess to specific user interface settings.

BRIEF SUMMARY OF THE INVENTION

The present invention overcomes the aforementioned drawbacks byproviding a system and method for marking specific settings for eachuser interface device of a welding-type system. Specifically, a varietyof marking systems and parameter recording systems are provided that arecoupled directly with each specific user interface device. For example,the provided systems aid in recording and indicating settings includingbut not limited to wire feed speed on a wire feeder and the appropriatevoltage on the power supply.

In accordance with one aspect of the present invention, a welding-typesystem is disclosed that includes a housing forming an enclosure and apower supply arranged within the enclosure to deliver welding-type powerduring a welding-type process. The welding-type system also includes auser interface having a user interface device configured to selectoperational parameters of the welding-type process. Furthermore, thewelding-type system includes a bezel forming a marking surface thatextends about at least a portion of a periphery of the interface deviceto display user markings and allow the markings to be selectivelyerased.

In accordance with another aspect of the present invention, awelding-type system is disclosed that includes a housing forming anenclosure and a power supply arranged within the enclosure to deliverwelding-type power during a welding-type process. The welding-typesystem also includes a user interface having at least one dialconfigured to select operational parameters of the welding-type process.A pointer is coupled with the dial and is independently movable withrespect to the dial to indicate a desired dial setting.

In accordance with yet another aspect of the invention, a welding-typesystem is disclosed that includes a housing forming an enclosure and apower supply arranged within the enclosure to deliver welding-type powerduring a welding-type process. The welding-type system also includes auser interface having a user interface device configured to selectoperational parameters of the welding-type process. A marking surfaceextends along a periphery of the interface device that is designed toreceive color-coded markers that engage the marking surface throughsuction, magnetism, or peg-and-receptacle couplings to indicate desiredsettings of the interface device to perform the welding-type process.

Various other features of the present invention will be made apparentfrom the following detailed description and the drawings.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

The invention will hereafter be described with reference to theaccompanying drawings, wherein like reference numerals denote likeelements, and:

FIG. 1 is a front elevational view of a welding-type system including aworkflow/parameter tracking system in accordance with the presentinvention;

FIG. 2 is a detailed front elevational view of a user interface for thewelding-type system of FIG. 1 including the workflow/parameter trackingsystem in accordance with the present invention; and

FIG. 3 is a detailed front elevational view of a user interface for awire feeder included in the welding-type system of FIG. 1 including theworkflow/parameter tracking system in accordance with the presentinvention.

DETAILED DESCRIPTION OF THE INVENTION

Referring now to FIG. 1, a multiple-operator arc welding system 10 isshown that includes six welding modules 12-22 arranged in a commonhousing 24 forming an enclosure. The multiple-operator arc weldingsystem 10 is just one example of a welding-type system with which thepresent invention can be incorporated. Specifically, the presentinvention is equivalently applicable to single operator welding-typesystems of any modality. Similarly, the present invention isequivalently applicable to other welding-type systems that utilizewelding-type power, such as plasma cutters and induction heaters.Therefore, though the present invention will be described with respectto the multiple-operator arc welding system 10 of FIG. 1 and the userinterfaces included with such systems, the present invention isequivalently applicable to any other welding-type system or modality.

Each welding module 12-22 of the multiple-operator arc welding system 10is designed to operate as an independent welding power source.Therefore, each welding module 12-22 includes a respective userinterface 26-36 designed to allow operator selection of operationalparameters for a welding-type process.

A negative weld cable 38 extends from a negative weld terminal 39 of awelding module 12 and is clamped to a workpiece 40. Additionally, apositive weld cable 42 extends from a positive terminal 44 of thewelding module 12 to a remote wire feeder 46 and welding torch 48. Usingthis arrangement, a welding-type process, such as a metal inert gas(MIG) welding-type process, can be performed. The user interface 26 ofthe welding module 12 and/or wire feeder 46 are used to select theoperational parameters of the welding-type process. As will bedescribed, the present invention provides a system and method forrecording and tracking the proper operational parameters, components ofthe welding-type system, and/or workflow procedures for a givenwelding-type process performed on a specific welding-type system orwelding module of a multiple-operator welding system 10.

Referring now to FIG. 2, an exemplary user interface 50 for controllinga welding-type system, such as an individual welding module 12-22 of themultiple-operator welding system of FIG. 1, is shown. The user interface50 includes a plurality of interface devices. Specifically, awelding-type process selection switch 52 is included that, in theillustrated user interface 50, allows selection between a MIG weldingprocess, a stick welding process with hot start, and a stick weldingprocess without hot start. A dig depth dial 54 is included having asetting pointer 55 for controlling a dig depth when the stick weldingprocess is selected. Additionally, an output selection switch 56 and acontrol selection switch 58 are provided that allow an operator toselect between controlling the power output parameters and other controlparameters from either the user interface 50 arranged on the individualwelding module 12-22 of FIG. 1 or, as will be described with respect toFIG. 3, at a remote location, such as through a wire feeder userinterface. The user interface 50 also includes a power output controldial 60 having a setting pointer 61 and an alert panel 62 that includesa high temperature shutdown indicator 64.

The above-described user interface devices are simply exemplary userinterface devices. That is, the systems and methods for tracking andrecording components, operational parameters, and workflow that will bedescribed below may be used with a wide variety of user interfacedevices. For example, while the above-described user interface 50includes dials, switches, and indicators, it is also contemplated thatbuttons, sliders, touch screens, and other user interface devices may beincluded.

One system for tracking and recording operational parameters includeswands or pointers 66, 68, 70, 72 that are coupled with the dials 54, 60.In one arrangement, it is contemplated that a pair of dials may becoupled with each dial 54, 60. In this arrangement, one pointer 66, 70functions as a minimum setting tracking pointer and the other pointer68, 72 functions as a maximum setting tracking pointer. That is, theminimum setting tracking pointers 66, 70 are configured to automaticallyrecord the minimum setting to which the dial 54, 60 has been set.Specifically, as the dials 54, 60 are rotated toward a minimum value,the minimum setting tracking pointers 66, 70 move to mirror the dialsetting pointers 55, 61 and remain in that minimum position even afterthe dial 54, 60 has be rotated away from the minimum value. That is, theminimum setting tracking pointers 66, 70 are independent from the dials54, 60 and only interact with the dials 54, 60 when a new minimumsetting is being made by an operator.

Additionally, an operator may choose to move the minimum settingtracking pointers 66, 70 from the last recorded minimum setting and, insome cases, may use the minimum setting tracking pointers 66, 70 tocreate a minimum stop setting. That is, it is contemplated that theminimum setting tracking pointers 66, 70 may be locked in a particularposition to create a minimum setting stop below which the dials 54, 60cannot be set. Furthermore, it is contemplated that the minimum settingtracking pointers 66, 70 may be controlled only by manual settings. Inthis case, the minimum setting tracking pointers 66, 70 are notautomatically moved to track a minimum setting of the dials 54, 60 andfunction only as an operator-selected reference setting.

The maximum setting tracking setting pointers 68, 72 are configured tofunction in a manner that is similar to the above-described minimumsetting tracking pointers 66, 70. That is, it is contemplated that themaximum setting tracking setting pointers 68, 72 are independent fromthe dials 53, 60 but are configured to automatically move with the dial54, 60 to a newly selected maximum setting. However, it is alsocontemplated that the maximum setting tracking setting pointers 68, 72may be configured to only move in response to manual settings.

Beyond the above-described minimum and maximum setting tracking pointers66-72, it is contemplated that additional pointers 74 may be included.These pointers 74 are configured to record specific manually selectedsettings. Such pointers 74 for recording particular user-selectedsettings are particularly useful when coupled with a marking surface 76.

The marking surface 76 extends about a periphery of the power outputcontrol dial 60 to form a bezel and is configured to allow an operatoror user to make markings 78, 80, 81 thereon that may be selectivelyerased. For example, an operator can create markings 78 on the markingsurface 76 that indicate the relevance of a particular pointer 74, suchas a desired power output setting when performing MIG welding using aparticular welding system. Additionally, it is contemplated that themarking surface 76 may include traditional settings indicators, such astextual labels 82 or dial setting gradients 84. Accordingly, asillustrated, an operator can augment the traditional settings indicators82, 84, such as by creating a marking 80 that extends over a portion ofthe dial setting gradient 84 to indicate that a particular portion ofthe dial setting should not be used. Similarly, it is contemplated thatan operator could augment textual labels 82 by creating a marking 81that further clarifies or annotates a textual label 82.

It is contemplated that the marking surface 76 may be formed by a dryerase marker board or similar surface that can be erasably marked with adry erase marker, chalk, or grease marker. Alternatively, it iscontemplated that the marking surface 76 may be formed by atouch-responsive display element that displays a mark in response to atouch from a stylus or a user's hand. In any case, the marking surface76 extends along a periphery of the interface devices in the userinterface 50 to display user markings that can be selectively erased.

In addition to marks 78, 80, 81 that are hand written on the markingsurface 76, it is contemplated that a variety of marker elements may beused to record and indicate settings, configurations, and/or workflows.For example, it is contemplated that portions of the user interface 50may include a plurality of holes 85 that are designed to receive pegs86. The pegs 86 can be arranged in particular holes 85 to indicate adesired setting of particular interface device. As illustrated, theholes 85 may be arranged proximate to a switch 52, such that the peg 86indicates a desired position of the switch 52. Additionally, it iscontemplated that the holes 85 may be arranged proximate to the dials54, 60 or other interface devices to indicate desired settings in asimilar manner. Furthermore, as will be described below, the pegs 86 maybe color coded to indicate that the desired settings correspond to aparticular welding-type process or to particular components of thewelding-type system.

Similarly, it is contemplated that the periphery of the user interfacedevices 52, 54, 56, 58, 60, 62 may be substantially continuous toreceive suction indicators 87 or have a substantially high permeabilityto receive magnetic indicators 88. In a manner similar to the hole 85and peg 86 system described above, the suction indicators 87 and themagnetic indicators 88 can be used to indicate desired settings and maybe color coded to indicate that the desired settings correspond to aparticular welding-type process or to particular components of thewelding-type system.

As addressed above, to further aid in correctly configuring awelding-type system for a particular welding-type process, it iscontemplated that the markings 78, 80, 81, indicators 86, 87, 88, and/orcomponents of the welding-type system may be color coded to facilitateproper selection of components and proper workflow when performing theparticular welding-type process.

For example, it is contemplated that an additional marking surface 89may be included for general notes, such as color coding information 90,91. In the illustrated example, the marking surface 89 includes operatormarks 90, 91 indicating that marks that are in “blue” correspond toinformation relevant to MIG welding processes and marks that are in“red” correspond to information relevant to stick welding processes.

Beyond color coded marks written on the user interface 50, it iscontemplated that individual components of the welding-type system maybe color coded and color coded setup and workflow reference guides maybe included. For example, in the welding-type system 10 illustrated inFIG. 1, components such as the wire feeder 46 and welding torch 48 mayinclude blue marks to indicate that these components are to be used withMIG welding processes. Continuing with the example of a MIG weldingprocess, after assembling the components having blue marks, the operatorthen arranges the user interface 50 of FIG. 2 using the bluemarkers/indicators. For example, the peg 86 could be color coded blueand be positioned to move the process selection switch 52 to the “MIG”setting. Similarly, the suction indicator 87 and magnetic indicator 88could be color coded blue and arranged as illustrated proximate to theoutput selection switch 56 and control selection switch 58,respectively, to indicate that both switches 56, 58 should be in the“remote” position during the MIG welding process. In this case, theoperator can control the MIG welding process from a remote userinterface, such as may be included on the wire feeder 46 of FIG. 1. Tofurther facilitate proper setup and workflow, a color coded workflowreference guide or book (not shown) may be provided.

Referring now to FIG. 3, a wire feeder user interface 92 is illustrated.While the illustrated wire feeder user interface 92 is relativelycomplex and includes a variety of interface devices, it is contemplatedthat the present invention is equivalently applicable to any wire feederuser interface and, particularly, less complex wire feeder userinterfaces that are commonly included with wire feeders. Similarly, inthe case of induction heaters, the present invention may be associatedwith a user interface of a remote pendant control.

The user interface 92 includes an upper display 94 configured to displayvoltage and/or time information. Specifically, when displaying voltageinformation on the upper display 94, a voltage labeled light emittingdiode (LED) 96 is illuminated. An upper display button 98 can bedepressed to display or adjust weld time. An upper display button LED100 accompanies the upper display button 98 to indicate when informationdisplayed in the upper display 94 may be adjusted by an adjustmentcontrol 102. By rotating the adjustment control 102 it is possible toincrement or decrement the selected item. To change the informationdisplayed on the upper display 94 from voltage to time informationrelating to the duration of a welding sequence, the upper display button98 can be depressed and the voltage LED 96 is turned off in favor of atime LED 104.

A second, lower display 106 is also included. The lower display 106displays wire feed speed (WFS) or amperage (current) information. Whendisplaying WFS, a WFS LED 108 is illuminated. Accompanying the lowerdisplay 106 is a lower display button 110 that may be depressed todisplay, input, or allow adjustment of either the WFS or current. Thelower display button 110 can be used to cause the lower display 106 todisplay current in amps. If current is displayed, an Amps LED 112 isilluminated. A lower display button LED 114 is illuminated to indicatewhen it is possible to adjust the information displayed in the lowerdisplay 106. When the lower display button LED 114 is illuminated, theadjustment control 102 can be used to adjust the value of the displayeditem, that is, WFS or current.

A program display 116 is also included in the wire feeder user interface92. The program display 116 is dedicated to displaying informationrelating to the active or queued programs. A program button 118 allows auser to activate a program select feature. By pressing the programbutton 118 and rotating the adjustment control 102 the user can cyclethrough and select various welding programs. A display button LED 120 isilluminated to indicate when the adjustment control 102 is enabled toadjust a program displayed in the program display 116.

A sequence button 122 is included to allow user selection of weldingsequences. Accompanying the sequence button 122 are LEDs that correspondto sections of the welding sequence. Specifically, the user interface 92includes three LEDs that indicate whether the welding sequence is in oneof three sections of the welding sequence: start 124, crater 126, orpre-postflow 128.

Finally, a setup button 130 is included that allows a user to select themode of operation. The setup button 130 allows the user to cycle througha plurality of menus. In one embodiment, the menus include a mode menu,a run-in menu, a burn-back menu, and a units menu. The mode menu allowsa user to make a mode selection. For example, the mode selection mayinclude modes of constant current or constant voltage. The set up button130 includes an LED 132 that indicates when the adjustment control 102can be used to change setup parameters or cycle through setup menus.

In a manner similar to that described with respect to FIG. 2, it iscontemplated that the wire feeder user interface 92 may include one ormore marking surfaces. In the illustrated embodiment it is contemplatedthat each of the above-described user-interface devices may besurrounded by a common marking surface. That is, it is contemplated thata bezel extending about the above-described user-interface devices mayform a marking surface 134. Accordingly, a user or operator may createmarks 136-146 about any user-interface device to indicate thefunctionality of a given user-interface device, a particular workflow,and/or a desired setting. For example, the marking surface 134 can beused to indicate a desired setting for a particular welding process, forexample, the voltage or amperage setting when performing a welding-typeprocess on a steel workpiece 136. In this case, it is contemplated thatthe above-described LEDs 96, 100, 104, 108, 112, 114, 120, 124, 126,128, 132 may be color coded, such that particular markings 136 may besimilarly color coded to indicate that the setting recorded by themarking 136 corresponds to a particular operational parameter indicatedby a specific LED 96, 100, 104, 108, 112, 114, 120, 124, 126, 128, 132.Additionally, it is contemplated that the marking surface 134 may bemarked 138, 146 to indicate operational functions of a particularuser-interface components. Furthermore, the marking surface 134 may beused to record 140, 142, 144 the order of operational workflows.

The above-described system and method allows an operator to mark,record, and store specific settings for each user interface device of awelding-type system. Specifically, a variety of marking systems andparameter recording systems are provided that are coupled directly witheach specific user interface device.

The present invention has been described in terms of the variousembodiments, and it should be appreciated that many equivalents,alternatives, variations, and modifications, aside from those expresslystated, are possible and within the scope of the invention. Therefore,the invention should not be limited to a particular describedembodiment.

I claim:
 1. A welding system comprising: a housing forming an enclosure;a power supply arranged within the enclosure and configured to deliverwelding-type power during a welding-type process; a user interfaceincluding at least one user interface device configured to selectoperational parameters of a welding process; a bezel integrated into thehousing and forming a marking surface that extends about at least aportion of a periphery of the at least one user interface device todisplay user markings and allow the user markings to be selectivelyerased, wherein the marking surface includes: a touch-responsive displayelement configured to display a mark indicating a desired setting of theat least one user interface device in response to contact by a hand of auser along an area of the touch-responsive display corresponding to thedesired setting, and a dial setting gradient; and wherein the at leastone user interface device includes a dial comprising at least onepointer coupled with the dial and independently movable with respect tothe dial to indicate a desired dial setting and the dial extends over aportion of the dial setting gradient.
 2. The welding system of claim 1wherein the marking surface forms a dry erase marker board.
 3. Thewelding system of claim 1 wherein the user markings include at least oneof a dry erase marker, chalk, and a grease marker.
 4. The welding systemof claim 1 wherein the bezel includes a plurality of holes configured toreceive pegs indicating desired settings of the at least one userinterface device.
 5. The welding system of claim 1 wherein the markingsurface has a sufficient permeability to receive magnets arranged aboutthe periphery of the at least one user interface device indicatingdesired settings of the at least one user interface device.
 6. Thewelding system of claim 1 wherein the bezel is sufficiently continuousto receive suction indicators arranged about the periphery of the atleast one user interface device indicating desired settings of the atleast one user interface device.
 7. The welding system of claim 1wherein the bezel extends along peripheries of a plurality of interfacedevices to display user markings indicating at least one of a setupprocess and a workflow process designed to carry out the weldingprocess.